Battery System Cooling via Segmented Arrays and Interconnected Ducts
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Solution Overview
Problem
Conventional battery systems with layered rectangular/prismatic cells face challenges in maintaining uniform temperature, leading to uneven residual capacities and shortened service life due to increased temperature differences among cells, especially when a large number of cells are used.
Innovation Solution
A battery system design featuring a battery block with layered rectangular/prismatic cells and a cooling gap, where a forced gas blower circulates cooling gas through interconnected ducts to minimize temperature differences by dividing the cell array into two separate arrays, reducing pressure loss with a reinforced outer casing and intermediate ducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of rectangular/prismatic cells are layered to increase battery capacity, then the battery system can handle larger electric current, but the temperature difference among cells increases leading to shortened service life
Solution Approach 1:
The battery system divides the layered cells into two separate arrays and introduces an intermediate duct between them. This segmentation allows cooling gas to be distributed more effectively across all cells, reducing temperature differences and preventing over-charging or over-discharging of individual cells, thereby extending service life while maintaining high power capacity
2Temperature
If cooling gaps are defined between cells with spacers to enable cooling, then heat dissipation is improved, but the structure becomes more complex and manufacturing cost increases
Solution Approach 1:
The outer casing is designed to serve multiple functions: it provides structural support for the battery system, acts as a duct for cooling gas circulation, and includes reinforced portions that function as both structural strengthening and cooling gas passage ways. This multi-functionality reduces the need for separate cooling components, simplifying the overall structure while maintaining effective heat dissipation
3Device complexity
If natural convection cooling is used without forced gas circulation, then the system is simpler, but temperature uniformity among cells deteriorates
Solution Approach 1:
The system employs forced convection cooling by introducing a gas circulation path through the outer casing and intermediate ducts. Cooling gas is actively circulated through the cooling gaps between cells, ensuring uniform heat removal across all cells. This pneumatic approach overrides natural convection limitations and achieves superior temperature uniformity, which is critical for preventing cell degradation and extending service life
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively reduces temperature differences among cells, extending the service life of the battery system by maintaining a minimal temperature variance, as demonstrated by reducing the temperature difference from 5.8°C to 3.4°C in a system with 36 lithium-ion cells.
Implementation Method 1
a forced gas blower for forcibly blowing the gas through the cooling gap (4) in the battery block (3)
Data Source
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AI summary
A battery system includes: a battery block 3 defining a cooling gap 4 between battery cells 1 composed of a plurality of rectangular/prismatic cells; and a blower 9 forcibly blowing the gas through the gap 4 in the block 3. The block 3, set in two separate arrays, is provided therebetween with an intermediate duct 6 connected to each of the gaps 4. An outer duct 7 is provided outside the block 3 set in two separate arrays, and the plurality of gaps 4 are parallel-connected between the duct 7 and the duct 6. The gas, forcibly blown from the duct 6 to the duct 7, is branched from the duct 6 to be blown through each of the gaps 4 to cool the cells 1. The gas having passed through the gaps 4 and cooled the cells 1 is collected at and exhausted from the duct 7.